Company Overview Sajars Specialties Molding Specifications Large - - PowerPoint PPT Presentation

Company Overview

Sajar’s Specialties

Molding Specifications

Large Parts (10” to 80” horizontal, 10” to 70” vertical, Surface Area: In excess of 1,000 sq. in.) High Cosmetic Standards Conversions to Gas Assist Injection Molding Engineering Grade Polymers Part Consolidation for Cost Savings

Sajar Plastics: Key Figures

World Leader GAIM Revenues: $15M Sales: 50% GAIM Presses: 16 Building: >150,000 sq ft Employees: 95

Customer-Centric Commitment Intensive Technological advancements in GAIM Innovation to drive growth for customers Continually striving to be the best

Our Culture

Markets

Medical 50% Financial / Business 25% Laboratory 15% Industrial 10%

Customers

Engineering

Customer Support

• Design for manufacturability (DFM)
• Mold cost minimization
• Mold performance optimization

Broad CAD Capability

• SolidWorks, ProE, IGES, STEP, etc

CAE ANALYSIS

• Mold flow analysis
• Mechanical analysis (FEA)

Quality

ISO 9001-2015 certified

RoHS and Reach compliant

UL Yellow Card for Gas Assist Utilize CMM software Preventative Maintenance

Quality

Equipment

• Colorimetric Spectrophotometer
• Gloss Meter
• Cordax RS-150 measuring machine

Inspection Procedures

• Inspection procedure cards follow every work order
• Senior Quality Technician establishes working standard
• Quality inspectors perform first piece check in
• Continual inspection performed and documented by QC in molding,

finishing, and assembly every 1-2 hours

Backup Plan

Systems data Specification s

Log Sheets Procedures MRP QA docs Process Data BOMs Routers

• Data is backed up daily at an
• ffsite location
• Maximum exposure of data

loss – 1 day

• In the event of data loss,

customers will be notified

Decoration and Assembly

Decoration

• Mist Coat Painting (solvent / aqueous)
• Finish Gloss or Textured Painting (solvent / aqueous)
• Pad Printing
• Label Application

Assembly

• Complex Parts & Kits
• Electronics
• Sonically Welded Inserts
• Packaging

30 years of Experience with Gas Assist Over 500 Gas Assist parts commercialized Over 300 Gas Assist parts in production Proprietary nozzle design/technology World Leader in Gas Assist

Gas Assist

Process Characteristics:

• Part Cost: Low
• Tooling Cost: High
• Can produce intricate parts
• Large variety of polymers gives wide range of properties
• Can produce a wide range of part sizes with different press sizes

Injection Molding

Gas Assist Injection Molding

Gas Injection Molding uses a partial shot of plastic and high-pressure gas to finish filling the mold cavity. This process gives designers flexibility.

Process Characteristics:

• Tooling Cost: High
• Part Cost: Low
• Design Flexibility due to elimination of sink, warp, internal part stresses

associated with high pressure filling. Tight dimensional control

• Press size is reduced due to lower molding pressures
• Especially suited to large, complex parts with critical dimensions, high

cosmetics, and reverse features

Low-pressure injection molding process Requires a short shot

• f resin to fill a mold

High pressure N2 or CO2 gas injected after resin

Resin & Gas flow through mold

Gas Assist: Internal Process

Internal GAIM Diagrams

Gas Assist: Internal Benefits

Superior Aesthetics

• Excellent process for high profile, large, thick section parts
• Elimination of warp & sink marks
• Potential elimination of painting/finishing

Design Freedom

• Exceptional dimensional stability & tight tolerances
• Best for full geometry, thick parts
• Lighter weight
• Support ribs & bosses molded in

Gas Assist: Internal Benefits

Operational Advantages

• Reduction of resin material, and power consumption
• Reduction of mold pressures, residual stress, & wear on molds
• Decreased part and tooling costs
• Uniform pressure transmission over part surface
• Production of larger parts employing smaller presses = SAVINGS

Reduced Costs

Material savings from thinner walls – 0.140” Elimination of finishing Smaller, less expensive presses Coring

External Gas Assist: Process

Micro-thin layer of gas between back surface

• f part and mold core

Front surface of part forced against opposite side of mold cavity Improved replication of the part front surface

External Gas Assist: Benefits

Superior Aesthetics

• Best process for high profile, large surface area parts
• Further benefits on Large parts
• Elimination of warp & sink marks
• Potential elimination of Finishing

Design Freedom

• Exceptional dimensional stability & tight tolerances
• Greater rib width to nominal wall thickness (1:1 ratio)
• Support ribs & bosses molded in

Operational Advantages

• Reduction of mold pressures, residual stress, & wear on molds
• Enables larger moldings using smaller presses

External Gas Assist: Tooling

Mold needs sealed between core & component back

Split line Apertures Ejector pins Insert clearances

O-rings vs. Integral seals Location of gas nozzles Rib design

Production Process Selection

Reaction Injection Molding Gas Assist Injection Molding Thermoforming Structural Foam Straight Injection

High

Design Complexity/ Part Size

Low ~500 Parts Per Year

MOLD LDING TECHNOLO LOGY GAIM ADVANTAGES REASON / RESPONSIBLE LE FEATURE Struct uctur ural al Foam am

Less Weight Thinner walls can be designed; more environmentally friendly Less Finishing Cost Swirls and bubbles in structural foam require sanding, priming, and base painting

Thermof

• for
• rming

ng

Design Freedom GAIM can accommodate more complex part designs & part consolidation Much Wider Resin Selection Very few resin options for thick sheet thermoforming Lower Part Cost Much faster & less manual mfg process; GAIM best for >500 units/year Reverse features molded in Ribs and bosses must be glued or screwed to back of thermoformed parts, increasing expense Windows molded in Windows must be machined in for thermoformed parts, increasing expense Wall thickness control Far better wall thickness control with GAIM

Strai aigh ght Inject ection

• n

Design Freedom GAIM can accommodate larger & more complex part designs; part consolidation Elimination of sink & warp Gas pressure packs out areas where resin shrinkage is greatest (front side of ribs & bosses) Better dimensional control Lower required press tonnage means less residual stress in the finished parts Better surface cosmetics Gas pressure assures consistent surface and texture reproduction Reduce finishing and painting Better surface cosmetics (above) reduces sanding and priming on high profile parts (especially external gas assist) Larger moldings with smaller presses GAIM requires 1/3-1/2 of the molding pressure of straight injection molding.

React ction

• n Inject

ection

• n Moldi

ding ng

Much lower part cost Much faster & less manual mfg process; GAIM best for >500 units/year

(RIM)

Much Wider Resin Selection Very few resin options for RIM Better dimensional control Lower required press tonnage means less residual stress in the finished parts Better surface cosmetics Gas pressure assures consistent surface and texture reproduction; RIM requires extensive sanding & finishing

GAIM Advantages v Alternative Molding Technologies

Increase Design Freedom

Increase Part Size, Complexity, & Cosmetics Improve Physical Integrity with Integrated Ribs & Bosses Increase ribs & boss standoff sizes

• GAIM: Potentially no limits
• Straight Injection: 40-50% of nominal wall thickness

Thick areas cored with internal gas channels. Mold thick cross-sections in one piece

• Examples: A handle and work surface combined into one part

Hold tight tolerances on large parts Minimize warp over large flat surfaces Lower molded-in stress

• Part is packed from nearest gas channel rather than the gate
• Better chemical resistance due to lower molded in stress

Gas pressure is present in the entire cooling phase

• Not limited by gate freeze off (straight injection molding)

Exceptional Dimensional Stability

Allows production of larger parts on smaller presses

• Lower cost/hour
• Faster cycle time

Clamp tonnage rules

• GAIM: ~1.0-1.25 tons per sq in of part surface area
• Straight Inj.: ~3.5-4.5 tons per sq in of part surface area

Less pressure reduces warp on large, flat surfaces Cavity packing pressure applied by nitrogen gas

Reduce Cavity Pressure

Rapid Heat and Cool with Gas Assist (RHRC)

Purpose

• Imparts a glossy, Class A finish to unpainted, un-textured plastic parts

by eliminating weld lines, splay, and shadow marks on part surfaces

Process

• Quickly raise and lower temperature of mold surfaces
• Resin introduced to hotter mold surfaces
• Many methods to accomplish Rapid Heat and Cool (steam, hot water or

induction)

Additional Benefits

• Reduced fill pressure
• Filling very thin walls is possible
• No sink marks

Reaction Injection Molding (RIM)

Two highly reactive liquid ingredients are mixed and immediately injected into a mold cavity at low pressure and heated to the point where chemical reaction leading to solidification occur.

Process Characteristics:

• Part Cost: High
• Mold Cost: Low
• Cycle Time: High
• RIM polyurethane parts possess a foam internal structure surrounded

by a dense outer skin

• Common Materials include Polyurethane, Epoxies, Urea-formaldehyde

Reaction Injection Molding

Benefits:

• Low cost molds
• Complex designs possible
• Reverse side features are available

Shortcomings:

• Incredibly limited material selection
• Incredibly long cycle times due to slow polymer curing
• Poor dimensional repeatability
• Low impact resistance over time
• Cosmetic parts must be painted

Thermoforming

Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product.

Process Characteristics:

• Part Cost: High
• Tool Cost: Low
• Best for very low volume production
• Capable of producing very large parts
• Reverse side features (ribs/bosses) must be bonded to part.

Windows must be machined in

• Inconsistent wall thickness

Structural Foam Molding

Structural foam is well suited for large plastic parts as the foaming gas bubbles in the resin matrix pack out the resin and reduce the incidence of

• sink. These parts are usually very thick, nearly 0.250” wall thickness, and

are ideal for structural elements that will not be in view.

Process Characteristics

• Part Cost: Comparable to GAIM
• Tooling Cost: Comparable to GAIM
• Sink marks are reduced
• Parts have a swirl patterns and bubbles so they must be finished for

cosmetic purposes.

• Parts can be molded with thick cross sections
• Process can produce parts up to 100 lbs. and 12ft. X 10ft. in area.

Blow Molding

Blow molding is accomplished by vertically extruding a hollow tube (parison) of molten plastic. The parison is then clamped between two mold halves and expanded into the desired shape by inflating it with compressed air. After cooling, a hollow part emerges.

Process Characteristics

• Part Cost: Moderate
• Tooling Cost: Moderate
• Parts as large as 12ft. X 4ft. can be formed
• Blow molding produces parts with the highest strength to weight

ratio of any plastic process

• Complex, hollow parts are formed with no internal stresses

Rotational Molding

A method of casting hollow plastic parts with few restriction regarding size

• r complexity. Plastic powder is fused in a hollow female mold by rotating

it simultaneously in two directions while heating it in an oven. Once the plastic is fused, the mold is cooled to solidify the plastic and the part is removed by splitting the mold.

Process Characteristics

• Tooling Cost: Low for large parts
• Very stable parts – no molded in stress
• Can produce complex part geometries
• Can mold in metal inserts and graphics
• Suited for low volume production, especially of drums and tanks

Weld/Knit Lines（PMMA)

RHCM No Weld lines Conventional Molding Showing Weld line

36

High Gloss Surface Glass Filler（ABS+GF20%)

RHCM No Filler Exposure Conventional Molding Filler Exposure

37

Advantages of RHRC

38

Conventional Molding RHCM Molding

Weld/Knit lines visible not visible Flow Marks visible not visible Class A Surface Gloss difficult to obtain possible, even with filled resins Glass/Carbon Fillers Filler shows on surface Filler does not show on surface Transference of textures difficult to obtain fine transcription Fine textures are possible Post Mold Painting required not required Thin wall parts difficult (insufficient resin flow) possible Thick wall parts long cycle time cycle time reduction is possible Biodegradable resins long cycle time cycle time reduction is possible

Thank You

Contact Us

Nicole Greenway 15285 South State Street Middlefield, OH 44062 (440)-632-5203 www.sajarplastics.com